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    Modularization

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    SPKTCE
    Modularization is an approach where design, procurement, contracting and construction work is shifted away from the construction site to fabrication yards, including entire process structures, machines and other structures. Modularization is effective when there are client drivers like remote site access, severe weather, tight schedules, limited labor, or high density piping areas. The decision to modularize requires early commitment and affects engineering, procurement, fabrication, and installation. Benefits include improved safety, cost savings from productivity gains and reduced field work, and shortened schedule, but it also presents challenges like increased planning, engineering, and shipping costs.

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    Modularization

    Uploaded by

    SPKTCE
    312 views25 pages
    Modularization is an approach where design, procurement, contracting and construction work is shifted away from the construction site to fabrication yards, including entire process structures, machines and other structures. Modularization is effective when there are client drivers like remote site access, severe weather, tight schedules, limited labor, or high density piping areas. The decision to modularize requires early commitment and affects engineering, procurement, fabrication, and installation. Benefits include improved safety, cost savings from productivity gains and reduced field work, and shortened schedule, but it also presents challenges like increased planning, engineering, and shipping costs.

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    Modularization is an approach where design, procurement, contracting and construction work is shifted away from the construction site to fabrication yards, including entire process structures, machines and other structures. Modularization is effective when there are client drivers like remote site access, severe weather, tight schedules, limited labor, or high density piping areas. The decision to modularize requires early commitment and affects engineering, procurement, fabrication, and installation. Benefits include improved safety, cost savings from productivity gains and reduced field work, and shortened schedule, but it also presents challenges like increased planning, engineering, and shipping costs.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    312 views25 pages

    Modularization

    Uploaded by

    SPKTCE
    Modularization is an approach where design, procurement, contracting and construction work is shifted away from the construction site to fabrication yards, including entire process structures, machines and other structures. Modularization is effective when there are client drivers like remote site access, severe weather, tight schedules, limited labor, or high density piping areas. The decision to modularize requires early commitment and affects engineering, procurement, fabrication, and installation. Benefits include improved safety, cost savings from productivity gains and reduced field work, and shortened schedule, but it also presents challenges like increased planning, engineering, and shipping costs.

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    At a glance
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    Some of the key takeaways from the document are that modularization can provide safety, cost and schedule benefits but requires additional planning and engineering. Modularization is most effective for remote sites, severe weather conditions or tight schedules.

    Some benefits of modularization include improved safety by moving work to controlled environments, cost savings from increased productivity and reduced indirect costs, and potential schedule improvements by starting site construction sooner.

    Modularization is most effective when there are constraints like remote site access, severe weather, tight schedules, limited labor availability or extensive testing requirements. Industries that implement repeatable designs can also benefit from modularization.

    Modularization: When Is It Effective?

    Russell Shulz
    Project Director; Fluor

    Modularization
    Overview

    Introduction
    When is Modularization Effective?
    Industry Implementation of Modularization
    Industry Terminology
    When Modularization Decision Needs To Be Made
    Execution Approach Differences
    Benefits of Modularization
    Challenges
    Market Trend
    Conclusion
    Q&A

    Modularization
    Introduction

    Modularization is an
    execution approach for
    design, procurement,
    contracting and construction
    that shifts site construction
    hours away from the site
    Includes skids, preassemblies, entire process
    structures, machines, and
    other structures including
    bridges

    Modularization
    Introduction Very Large Module (>600Tons)

    Modularization
    Introduction Small Truck-able Module (<60Tons)

    Modularization
    Introduction Pipe Rack Modules

    Modularization
    Introduction Ship Mounted Module

    Modularization
    When is Modularization Effective?

    Client business drivers


    supporting module design:

    Remote site access


    Severe site weather constraints
    Schedule-driven improvement
    Limited availability of regional
    skilled labor/ imported
    construction labor/ man camps
    Extensive Factory Acceptance
    Testing (FAT) desired
    High module potential /
    repeatable facility construction
    High density piping areas
    May be the only option

    Modularization
    Industry Implementation of Modularization

    Modular facilities world-wide


    Fixed and floating offshore applications
    Onshore production and pipeline projects

    Remote arctic & temperate


    locations
    Remote from tidewater, with constraints of land
    transport logistics and cost

    Global Industries using


    Modularization

    Infrastructure (bridge sections, buildings)


    Power (HRSGs, equipment and piping, piperacks)
    Manufacturing and life sciences (process buildings)
    Mining (process facilities, piperacks)
    Upstream (offshore installations)
    Downstream (process equipment, piperacks)

    Modularization
    Industry Terminology
    Module Type

    Size

    Very Large Modules (VLMs)

    > 600 tons

    Large Modules

    100 to 600 tons

    Intermediate / Medium Modules

    60 to 100 tons

    Small / Truckable Modules

    60 tons or less

    Piperack Modules
    Skid-mounted Equipment Modules

    Hybrid Modules

    Partially in the fab. Yard


    Finished and assembled
    on site

    Barge / Ship Mounted Modules

    Such as FPSO, FSOs,


    FLNG

    Modularization
    When Modularization Decision Needs To Be Made
    1. Define Business
    Drivers
    2. Accumulate
    Information
    3. Strategic Evaluation
    4. Develop Alternative
    Cases
    5. Decide Level of
    Modularization and
    Complex
    Preassembly
    6. Develop Estimates,
    Quantities, and
    Schedules
    7. Complete Project
    Execution Plan

    Business
    Planning

    Scope
    Definition

    Preliminary
    Engineering

    Detailed
    Engineering

    Construction

    Modularization
    When Modularization Decision Needs To Be Made

    The decision to modularize on a project


    needs full and early commitment from all
    stakeholders.

    Modularization
    Execution Approach Differences
    ATTACHMENT 2
    Sheet 1 of 1

    MOD 2007 EL. 102000

    Early Engineering
    Early Procurement
    Activities Sequence
    Fabrication Organization
    Interface Management
    Operations &
    Maintenance

    COLUMN H/1

    8 FV-62313B-01

    LP CRUDE
    TRANSFER
    PUMP

    DESALTER RECYCLE
    WATER PUMP

    DESALTER

    MONORAIL

    16 BBAB
    DROP ZONE
    20 SDV 62301-01

    FOAM
    DELUGE
    SYSTEM

    20 MOV-62313B-01
    16 BBAB

    8 FV-62313A-01
    PLTF. EL. 102006

    LP CRUDE
    TRANSFER
    PUMP

    LP SEPARATOR
    20 MOV-62313A-01
    MONORAIL

    Modularization
    Benefits of Modularization

    Safety

    Projected
    Results

    Cost
    Modularization

    Schedule

    Project
    Risks

    Modularization
    Benefits of Modularization

    Safety
    Work shifted to
    controlled shop
    environment
    Reduced total
    site hours
    Reduced work at
    high elevations
    Potential
    reduction in
    crane usage

    Modularization
    Benefits of Modularization

    Modularization
    Benefits of Modularization

    Cost Savings
    Reduced quantities
    for smaller footprint
    Productivity gain for
    work shifted to
    module yard
    Reduced indirects
    with less field hours

    Modularization
    Benefits of Modularization
    Materials Quantities Comparison *
    Prime Account
    Quantity Delta (% )
    Excavation, Backfill &
    -5
    Piling
    Concrete
    -30
    Structural Steel
    45
    Mechanical Equipment
    0
    Piping
    -15
    Electrical
    -20
    Instrumentation
    0
    Insulation
    -15
    *Maximized Process Units and Pipe Racks Modularization

    Modularization
    Benefits of Modularization

    Labor Relocation to Module Yard(s)


    Direct Field Cost
    Civil
    Concrete
    Structural Steel
    Buildings
    Mechanical Equipment
    Piping
    Electrical
    Instrumentation
    Insulation
    Average*

    Percent Work in
    Module Yard(s)
    0%
    0%
    80%
    30%
    30%
    63%
    20%
    20%
    65%
    44%

    Modularization
    Challenges

    Increased Planning
    Logistics
    Engineering / Procurement
    Early Engineering / Procurement
    Increased Cost of Engineering
    Increased Shipping Cost
    Increased Steel Quantities
    Increased Equipment damage
    potential
    Additional rigging / lifting
    requirements
    Module plan interfaces

    Modularization
    Market Trend

    Modules are becoming more


    condensed
    Dependence on fit for purpose
    designs to drive down costs
    Start up times after minimized
    Shipping solutions are very
    creative, nothing to big or too
    small
    Project & risk management
    overcoming challenges to
    deliver success

    Modularization
    Conclusion

    When is it efficient to
    Modularize?
    Decision Timing & Planning
    Modularization Benefits and
    Challenges
    Owner operations personnel to
    be involved from start
    Design takes longer, but
    installation at site means overall
    project schedule improvement
    Complete project team buy-in
    and alignment

    Modularization

    Q&A

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